REGAL-BELOIT. Installation and Operation Manual. Variable Speed AC Motor Drives. Micro and PowerWash Series

Transcription

1 REGAL-BELOIT Variable Speed AC Motor Drives Micro and PowerWash Series Installation and Operation Manual

2 Manual Number: SB184 TABLE OF CONTENTS 1.0 GENERAL PRODUCTS COVERED IN THIS MANUAL PRODUCT CHANGES WARRANTY RECEIVING CUSTOMER MODIFICATION SpinMaster Micro Drive SPECIFICATIONS SpinMaster Micro Drive MODEL ENCLOSURE DESIGNATION SpinMaster Micro Drive DIMENSIONS SpinMaster Micro Drive RATINGS THEORY DESCRIPTION OF AC MOTOR OPERATION DRIVE FUNCTION DESCRIPTION INSTALLATION INPUT AC REQUIREMENTS VOLTAGE SELECTION POWER WIRING SpinMaster Micro Drive POWER WIRING DIAGRAM INITIAL POWER UP KEYPAD CONTROL KEYPAD FUNCTIONS SpinMaster Micro Drive DISPLAY CONTROL WIRING GENERAL START/STOP AND SPEED CONTROL SpinMaster Micro Drive CONTROL WIRING DIAGRAMS SpinMaster Micro Drive TERMINAL STRIP TWO-WIRE START/STOP CONTROL THREE-WIRE START/STOP CONTROL SPEED POT AND PRESET SPEED CONTROL PROGRAMMING THE SpinMaster Micro DRIVE PROGRAMMING THE PARAMETERS PARAMETER ACCESS USING SPEED DIAL PARAMETER MENU DESCRIPTION OF PARAMETERS TROUBLESHOOTING USER SETTING RECORD

3 IMPORTANT NOTICE The following, and information is supplied to you for your protection and to provide you with many years of trouble free and safe operation of your Marathon Electric product. Hazard of electrical shock! Disconnect incoming power and wait three minutes before servicing the drive. Capacitors retain charge after power is removed. Hazard of electrical shock! Wait three minutes after disconnecting incoming power before servicing drive. Capacitors retain charge after power is removed. If CONTROL is set to LOCAL, TB-1 is disabled and CANNOT be used as a STOP switch! Incorrect use of TB-1 may result in damage to equipment and/or injury to personnel! See Parameter 30 - CONTROL. STOP (TB-1) and EXTERNAL FAULT (TB-13D) circuitry may be disabled if parameters are reset to factory defaults! The drive must be reprogrammed after a RESET in order to insure proper operation (see Parameter 65 - PROGRAM). FAILURE TO DO SO MAY RESULT IN DAMAGE TO EQUIPMENT AND/OR INJURY TO PERSONNEL! Consult motor manufacturer before operating motor above rated frequency. Overspeeding the motor and/or driven equipment can cause damage to equipment and injury to personnel! This method requires TB-13C to be set for RUN REVERSE, which will disable TB-1 as a STOP switch! Incorrect use of TB-1 may result in damage to equipment and/or injury to personnel! Refer to Parameter 49 - TB13C. If TB-13C is programmed for RUN REVERSE, TB-1 is disabled and CANNOT be used as a STOP switch! This is true in LOCAL and REMOTE mode. Incorrect use of TB-1 may result in damage to equipment and/or injury to personnel! Refer to Parameter 49 - TB-13C for more information. Automatic start of equipment may result in damage to equipment and/or injury to personnel! Automatic start should only be used on equipment that is inaccessible to personnel. DRIVES MUST NOT BE INSTALLED WHERE SUBJECTED TO ADVERSE ENVIRONMENTAL CONDITIONS! DRIVES MUST NOT BE INSTALLED WHERE SUBJECTED TO: COMBUSTIBLE, OILY, OR HAZARDOUS VAPORS OR DUST; EXCESSIVE MOISTURE OR DIRT; STRONG VIBRATION; EXCESSIVE AMBIENT TEMPERATURES. CONSULT CUSTOMER SERVICE FOR MORE INFORMATION ON THE SUITABILITY OF A DRIVE TO A PARTICULAR ENVIRONMENT. Severe damage to the drive can result if it is operated after a long period of storage or inactivity without reforming the DC bus capacitors! Do not connect incoming AC power to output terminals T1, T2, or T3! Severe damage to the drive will result. DO NOT connect incoming AC power to output terminals T1, T2, and T3! Do not cycle input power to the drive more than once every two minutes. Damage to the drive will result. When operating in JOG mode, the STOP key WILL NOT stop the drive. To stop the drive, the contact between TB-13B and TB-2 must be opened.

4 IMPORTANT NOTICE (continued) Consult qualified personnel with questions. All electrical repairs must be performed by trained and qualified personnel only. Consult motor manufacturer before operating motor and/or driven equipment above base speed. Resale of Goods: In the event of the resale of any of the goods, in whatever form, Resellers/Buyers will include the following language in a conspicuous place and in a conspicuous manner in a written agreement covering such sale: The manufacturer makes no warranty or representations, express or implied, by operation of law or otherwise, as to the merchantability or fitness for a particular purpose of the goods sold hereunder. Buyer acknowledges that it alone has determined that the goods purchased hereunder will suitably meet the requirements of their intended use. In no event will the manufacturer be liable for consequential, incidental or other damages. Even if the repair or replacement remedy shall be deemed to have failed of its essential purpose under Section of the Uniform Commercial Code, the manufacturer shall have no liability to Buyer for consequential damages. Resellers/Buyers agree to also include this entire document including the warnings and cautions above in a conspicuous place and in a conspicuous manner in writing to instruct users on the safe usage of the product.

5 1.0 GENERAL 1.1 PRODUCTS COVERED IN THIS MANUAL This manual covers the REGAL-BELOIT CORPORATION SpinMaster Micro and PowerWash Variable Frequency Drive. 1.2 PRODUCT CHANGES REGAL-BELOIT CORPORATION reserves the right to discontinue or make modifications to the design of its products and manuals without prior notice, and holds no obligation to make modifications to products sold previously. REGAL-BELOIT CORPORATION also holds no liability for losses of any kind which may result from this action. Instruction manuals are available for download from WARRANTY REGAL-BELOIT CORPORATION warrants the SpinMaster Micro Series AC motor control to be free of defects in material and workmanship for a period of eighteen months from the date of sale to the user, or two years from the date of shipment, which ever occurs first. A SpinMaster control, or any component contained therein, which under normal use, becomes defective within the stated warranty time period, shall be returned to REGAL-BELOIT CORPORATION, freight prepaid, for examination (contact Customer Service for authorization prior to returning any product). REGAL-BELOIT CORPORATION reserves the right to make the final determination as to the validity of a warranty claim, and sole obligation is to repair or replace only components which have been rendered defective due to faulty material or workmanship. No warranty claim will be accepted for components which have been damaged due to mishandling, improper installation, unauthorized repair and/or alteration of the product, operation in excess of design specifications or other misuse, or improper maintenance. REGAL-BELOIT CORPORATION makes no warranty that its products are compatible with any other equipment, or to any specific application, to which they may be applied and shall not be held liable for any other consequential damage or injury arising from the use of its products. This warranty is in lieu of all other warranties, expressed or implied. No other person, firm or corporation is authorized to assume, for REGAL-BELOIT CORPORATION, any other liability in connection with the demonstration or sale of its products. 1

6 1.4 RECEIVING Inspect all cartons for damage which may have occurred during shipping. Carefully unpack equipment and inspect thoroughly for damage or shortage. Report any damage to carrier and/or shortages to supplier. All major components and connections should be examined for damage and tightness, with special attention given to PC boards, plugs, knobs and switches. 1.5 CUSTOMER MODIFICATION REGAL-BELOIT CORPORATION, its sales representatives and distributors, welcome this opportunity to assist our customers in applying our products. Many customizing options are available to aid in this function. REGAL-BELOIT CORPORATION cannot assume responsibility for any modifications not authorized by its engineering department. 2

7 2.0 SpinMaster PowerWash SPECIFICATIONS Storage Temperature -20 to 70 C Ambient Operating Temperature Type 1 (IP 31) -10 to 50 C (With 2.5, 6 and 8 khz carrier, Type 4 (IP 65) -10 to 40 C derate for higher carriers) Type 12 (IP 54) -10 to 40 C Ambient Humidity Altitude Input Line Voltages Less than 95% (non-condensing) 3300 feet (1000 m) above sea level without derating 240/120 Vac, 240/200 Vac, 480/400 Vac, and 590/480 Vac Input Voltage Tolerance +10%, -15% Input Frequency Tolerance Output Wave Form Output Frequency Carrier Frequency 48 to 62 Hz Sine Coded PWM Hz, Optional up to 1000 Hz 2.5 khz to 14 khz Frequency Stability ± % / C Service Factor 1.00 Efficiency > 97% throughout speed range Power Factor (displacement) > 0.96 Overload Current Capacity Speed Reference Follower Control Voltage Analog Outputs Digital Outputs 150% of output rating for 60 seconds 180% of output rating for 30 seconds 0-10 VDC, 4-20 ma 15 VDC 0-10 VDC, or 2-10 VDC Proportional to speed and load Form C relay: 2A at 28 VDC or 120 Vac Open-collector outputs: 40 ma at 30 VDC 3

8 3.0 SpinMaster Micro DRIVE MODEL ENCLOSURE DESIGNATION HP VOLTAGE PHASE NEMA 1 NEMA 4 NEMA 4X NEMA /240 1 T1110 T400 T /240 1 T1112 T402 T /240 3 T1212 T422 T /240 1 T1114 T404 T /240 3 T1214 T424 T T1414 T434 T T15144 T444 T /240 1 T1115 T405 T /240 T1215 T425 T T1116 T406 T /240 3 T1216 T426 T T1416 T436 T T1516 T446 T T1117 T407 T /240 3 T1217 T427 T T1417 T437 T T1517 T447 T /240 3 T1218 T438 T T1418 T438 T T1518 T448 T /240 3 T1219 T429 T T1419 T439 T T1519 T449 T /240 3 T1220 T430 T T1420 T440 T T1520 T450 T /240 3 T1221 T431 T T1421 T441 T T1521 T451 T /240 3 T1222 T T1422 T442 T T1522 T453 T /240 3 T1223 T T1423 T T1523 T /240 3 T1224 T T1424 T T1524 T T1425 T T1525 T T1426 T T1526 T T1427 T T1527 T557 4

9 4.0 SpinMaster Micro DIMENSIONS 4.1 SpinMaster NEMA 1 Enclosed W D R H P N Q Q CONDUIT HOLES: S DIA DIA. S DIA. W T DIA. SLOT U V 1.00 R MOUNTING TAB DETAIL IF W 7.86 T = 0.20 U = 0.34 V = 0.19 IF W = T = 0.28 U = 0.44 V = 0.24 INPUT HP VOLTAGE MODEL H W D N P Q R S /240 T /240 T /240 T /240 T /240 T T T /240 T /240 T T /240 T T T T /240 T T T

10 4.1 SpinMaster NEMA 1 Enclosed (continued) INPUT HP VOLTAGE MODEL H W D N P Q R S 208/240 T T T /240 T T T /240 T T T /240 T T T /240 T T T /240 T T T /240 T T T T T T T T T

11 4.2 PowerWash NEMA 4 AND 4X Enclosed INPUT NEMA 4 NEMA 4X HP VOLTAGE MODEL MODEL H W D N P Q R S /240 T400 T /240 T402 T /240 T422 T /0240 T404 T /240 T424 T T434 T T444 T /240 T405 T /240 T425 T T406 T /240 T426 T T436 T T446 T T407 T /240 T427 T T437 T T447 T

12 4.2 PowerWash NEMA 4 AND 4X Enclosed (continued) INPUT TYPE 4 TYPE 4X HP VOLTAGE MODEL MODEL H W D N P Q R S 208/240 T428 T T438 T T448 T /240 T429 T T439 T T449 T /240 T430 T T440 T T450 T /240 T431 T T441 T T451 T /240 (See NEMA 12) T442 T T452 T

13 4.3 SpinMaster NEMA 12 Enclosed INPUT NEMA 12 HP VOLTAGE MODEL H W D N P Q R S 208/240 T N/A (See NEMA 4 or 4X) 575 N/A (See NEMA 4 or 4X) 208/240 T T T /240 T T T T T T T T T

14 5.0 SpinMaster Micro Drive RATINGS The following tables indicate the input and output ratings of the SpinMaster Micro drive series. NOTE: The output current ratings are based on operation at carrier frequencies of 8 khz and below. At full ambient temperature, operation at carrier frequencies above 8 khz require derating the drive by multiplying the output current rating by the following factors: 0.94 at 10 khz, 0.89 at 12 khz, and 0.83 at 14 khz. Refer to Parameter 23 - CARRIER in Section DESCRIPTION OF PARAMETERS. SpinMaster Micro Drive 120/240 Vac Ratings Models Input Output (Note 1) (120/240 Vac, Hz) (0-230 Vac) Nominal Nominal Current Current Rated Input (Amps) Power (Amps) Power HP Phase (Note 2) (KVA) (Note 2) (KVA) T1110, T400, T / / T1112, T402, T / / T1114, T404, T / / T1115, T405, T / / NOTE 1: See Section 3 for Drive Enclosures NOTE 2: N/A NOTE 3: See Section 8.0 for recommended fuse type. 10

15 SpinMaster Micro Drive RATINGS (continued) SpinMaster Micro Drive 208/240 Vac Ratings Models Input Output (Note 1) (240 Vac, Hz) (0-230 Vac) Nominal Nominal Current Current Rated Input (Amps) Power (Amps) Power HP Phase (Note 2) (KVA) (Note 2) (KVA) T1112, T402, T T1214, T424, T T1215, T405, T T1116, T406, T T1117, T407, T T1217, T427, T T1218, T428, T T1219, T429, T T1220, T430, T T1221, T431, T T1222, T T1223, T T1224, T NOTE 1: See Section 3 for Drive Enclosures NOTE 2: For 200 VAC Input Voltage Models (Three Phase only) multiply the input and output current ratings by 1.15 and the output voltage by NOTE 3: See Section 8.0 for recommended fuse type. 11

16 SpinMaster Micro Drive RATINGS (continued) SpinMaster Micro Drive 480 Vac Ratings Models Input Output (Note 1) (480 Vac, Hz) (0-460 Vac) Nominal Nominal Current Current Rated Input (Amps) Power (Amps) Power HP Phase (Note 2) (KVA) (Note 2) (KVA) T1414, T434, T T1416, T436, T T1417, T437, T T1418, T438, T T1419, T439, T T1420, T440, T T1421, T441, T T1422, T442, T T1423, T T1424, T T1425, T T1426, T T1427, T NOTE 1: See Section 3 for Drive Enclosures NOTE 2: For 400 VAC Input Voltage Models (Three Phase only) multiply the input and output current ratings by 1.15 and the output voltage by NOTE 3: See Section 8.0 for recommended fuse type. 12

17 SpinMaster Micro Drive RATINGS (continued) SpinMaster Micro Drive 575 Vac Ratings Models Input Output (Note 1) (590 Vac, Hz) (0-575 Vac) Nominal Nominal Current Current Rated Input (Amps) Power (Amps) Power HP Phase (Note 2) (KVA) (Note 2) (KVA) T1514, T444, T T1516, T446, T T1517, T447, T T1518, T448, T T1519, T449, T T1520, T450, T T1521, T451, T T1522, T453, T T1523, T T1524, T T1525, T T1526, T T1527, T NOTE 1: See Section 3 for Drive Enclosures NOTE 2: For 480 VAC Input Voltage Models (Three Phase only) multiply the input and output current ratings by 1.15 and the output voltage by NOTE 3: See Section 8.0 for recommended fuse type. 13

18 6.0 THEORY 6.1 DESCRIPTION OF AC MOTOR OPERATION Three phase AC motors are comprised of two major components, the stator and the rotor. The stator is a set of three electrical windings held stationary in the motor housing. The rotor is a metal cylinder, fixed to the motor drive shaft, which rotates within the stator. The arrangement of the stator coils and the presence of three phase AC voltage give rise to a rotating magnetic field which drives the rotor. The speed at which the magnetic field rotates is known as the synchronous speed of the motor. Synchronous speed is a function of the frequency at which the voltage is alternating and the number of poles in the stator windings. The following equation gives the relation between synchronous speed, frequency, and the number of poles: Ss f/p Where: Ss = Synchronous speed (rpm), f = frequency (Hz), p = number of poles In three phase induction motors the actual shaft speed differs from the synchronous speed as load is applied. This difference is known as slip. Slip is commonly expressed as a percentage of synchronous speed. A typical value is three percent at full load. The strength of the magnetic field in the gap between the rotor and stator is proportional to the amplitude of the voltage at a given frequency. The output torque capability of the motor is, therefore, a function of the applied voltage amplitude at a given frequency. When operated below base (rated) speed, AC motors run in the range of constant torque. Constant torque output is obtained by maintaining a constant ratio between voltage amplitude (Volts) and frequency (Hertz). For 60 Hz motors rated at 230, 460, and 575 Vac, common values of this V/Hz ratio are 3.83, 7.66, and 9.58 respectively. Operating with these V/Hz ratios generally yields optimum torque capability. Operating at lower ratio values results in lower torque and power capability. Operating at higher ratio values will cause the motor to overheat. Most standard motors are capable of providing full torque output from 3 to 60 Hz. However, at lower speeds, where motor cooling fans become less effective, supplemental cooling may be needed to operate at full torque output continuously. If the frequency applied to the motor is increased while the voltage remains constant, torque capability will decrease as speed increases. This will cause the horsepower capability of the motor to remain approximately constant. Motors run in this mode when operated above base speed, where drive output voltage is limited by the input line voltage. This operating range is known as the constant horsepower range. The typical maximum range for constant horsepower is about 2.3 to 1 (60 to 140 Hz). The diagram on the next page depicts the characteristics of a typical AC induction motor with a 60 Hz base speed. Consult motor manufacturer before operating motor and/or driven equipment above base speed. 14

19 6.1.1 VARIABLE TORQUE VS. CONSTANT TORQUE Variable frequency drives, and the loads they are applied to, can generally be divided into two groups: constant torque and variable torque. Constant torque loads include: vibrating conveyors, punch presses, rock crushers, machine tools, and just about every other application that is not considered variable torque. Variable torque loads include centrifugal pumps and fans, which make up the majority of HVAC applications. Variable torque loads are governed by the affinity laws, which define the relationships between speed, flow, torque and horsepower. The diagram below illustrates these relationships: 15

20 Variable torque refers to the fact that the torque required varies with the square of the speed. Also, the horsepower required varies with the cube of the speed, resulting in a large reduction in horsepower for even a small reduction in speed. It is easily seen that substantial energy savings can be achieved by reducing the speed of a fan or pump. For example, reducing the speed to 50% results in a 50 HP motor having to produce only 12.5% of rated horsepower, or 6.25 HP. Variable torque drives usually have a low overload capacity (110% - 120% for 60 seconds), because variable torque applications rarely experience overload conditions. To optimize efficiency and energy savings, variable torque drives are usually programmed to follow a variable V/Hz ratio. The term constant torque is not entirely accurate in terms of the actual torque required for an application. Many constant torque applications have reciprocating loads, such as vibrating conveyors and punch presses, where the rotational motion of the motor is being converted to a linear motion. In such cases, the torque loads, this fluctuation in torque is not a direct function of speed, as it is with a variable torque load. As a result, constant torque drives typically have a high overload rating (150% for 60 seconds) in order to handle the higher peak torque demands. To achieve maximum torque, constant torque drives follow a constant V/Hz ratio. SpinMaster PowerWash drives have full overload capacity (150% for 60 seconds, 180% for 30 seconds), so that either one can be used for either type of application. The V/Hz ratio can also be changed to optimize performance for either type of application. 6.2 DRIVE FUNCTION DESCRIPTION The SpinMaster Micro Series Drives are a 16 bit microprocessor based, keypad programmable, variable speed AC motor drive. There are four major sections: an input diode bridge and filter, a power board, a control board, and an output intelligent power module DRIVE OPERATION Incoming AC line voltage is converted to a pulsating DC voltage by the input diode bridge. The DC voltage is supplied to the bus filter capacitors through a charge circuit which limits inrush current to the capacitors during power-up. The pulsating DC voltage is filtered by the bus capacitors which reduces the ripple level. The filtered DC voltage enters the inverter section of the drive, composed of six output intelligent insulated gate bi-polar transistors (IGBTs) which make up the three output legs of the drive. Each leg has one intelligent IGBT connected to the positive bus voltage and one connected to the negative bus voltage. Alternately switching on each leg, the intelligent IGBT produces an alternating voltage on each of the corresponding motor windings. By switching each output intelligent IGBT at a very high frequency (known as the carrier frequency) for varying time intervals, the inverter is able to produce a smooth, three phase, sinusoidal output current wave which optimizes motor performance CIRCUIT DESCRIPTION The control section consists of a control board with a 16 bit microprocessor, keypad and display. Drive programming is accomplished via the keypad or the serial communications port. 16

21 During operation the drive can be controlled via the keypad, by control devices wired to the control terminal strip, or by the serial communications port. The Power Board contains the control and protection circuits which govern the six output IGBTs. The Power Board also contains a charging circuit for the bus filter capacitors, a motor current feedback circuit, a voltage feedback circuit, and a fault signal circuit. The drive has several built in protection circuits. These include phase-to-phase and phase-to-ground short circuit protection, high and low line voltage protection, protection against excessive ambient temperature, and protection against continuous excessive output current. Activation of any of these circuits will cause the drive to shut down in a fault condition SpinMaster Micro Drive ANALOG INPUT SIGNALS The drive allows for three speed reference input signals: speed potentiometer (10,000 Ohm), 4-20 ma, or 0-10 VDC. For control by a speed pot, the wiper lead is connected to terminal TB-5A, and the high and low end leads are connected to terminals TB-6 and TB-2, respectively. For 4-20 ma control, wire the positive to terminal TB-5B and the negative to terminal TB-2. For 0-10 VDC control, wire the positive to terminal TB-5A and the negative to terminal TB-2. Refer to the diagrams in Section SpinMaster Micro Drive CONTROL WIRING DIAGRAMS. The input impedance of terminal TB-5A (0-10 VDC input) is 200 kilohms, and the input impedance of terminal TB-5B (4-20 ma input) is 100 ohms. Terminal TB-2 is circuit common SpinMaster Micro Drive ANALOG OUTPUT SIGNALS There are two terminals that can supply analog output signals proportional to output frequency or load. Terminal TB-10A can provide a 0-10 VDC or a 2-10 VDC signal proportional to output frequency, and TB-10B can provide the same signals proportional to load. The 2-10 VDC signals can be converted to a 4-20 ma signal using a resistor in series with the signal such that the total circuit resistance is 500 Ohms. See Parameters: 42 - TB10A OUT, TB10B OUT, and 45 in Section DESCRIPTION OF PARAMETERS. NOTE: These analog output signals cannot be used with loop-powered devices that derive power from a 4-20 ma signal SpinMaster Micro Drive STATUS OUTPUT RELAYS The control board has one Form C relay at terminals TB-16, TB-17, and TB-18. Contacts are rated for 2 amps at 28 VDC or 120 Vac. There are also two open-collector outputs at terminals TB-14 and TB-15. The open-collector circuit is a current sinking type rated at 30 VDC and 40 ma maximum. An external power supply (30 VDC max.) must be used to power the open-collector outputs. The drive does not have a dedicated power supply for the open-collector outputs. The Form C relay and the open-collector outputs can be programmed to indicate any of the following: RUN, FAULT, /FAULT (INVERSE FAULT), LOCK (FAULT SPEED (AT SPEED), ABOVE #3, I LIMIT (CURRENT LIMIT), OR AUTO/MAN mode. See Parameters: 52 - TB14 OUT, 53 - TB15 OUT, and 54 - RELAY, in Section DESCRIPTION OF PARAMETERS. 17

22 The following describes the possible relay output settings: NONE RUN FAULT This setting disables the relay output. The relay energizes when the drive is given a START command, and remains energized until: a STOP command is given and the output frequency has decelerated to 0.5 Hz, the drive has tripped, or the input voltage is removed. Note that this relay indicates only that the drive is in the RUN mode. It does not necessarily indicate that the motor is turning. The relay energizes when input voltage is applied to the drive and remains energized until the drive trips into a fault condition, or input voltage is removed. / FAULT INVERSE FAULT The relay energizes when the drive trips into a fault condition, and remains energized until the fault condition is cleared. SPEED ABOVE #3 I LIMIT AUT/MAN FAULT LOCKOUT This relay is used when the drive is programmed to automatically restart after a fault. The relay energizes when input voltage is applied to the drive and remains energized until the drive has faulted and unsuccessfully attempted five restarts, or input voltage is removed. AT SPEED The relay energizes when the drive reaches the speed setpoint. To avoid a chattering relay (energizing and de-energizing), due to small fluctuations in speed, the relay will remain energized as long as the actual speed is within ±3 Hz of the speed setpoint. ABOVE SPEED #3 The relay energizes when the output frequency exceeds the SPEED #3 value, and de-energizes when the output frequency returns to a value lower than the SPEED #3 value. See Parameter 3 - SPEED #3 in Section DESCRIPTION OF PARAMETERS. CURRENT LIMIT The relay energizes when the drive is operating in current limit. Once the current limit relay is energized, it remains energized for a minimum of 500ms, regardless of whether the drive is still in current limit. At the end of the 500ms interval, the relay will de-energize if the drive is no longer in current limit. See Parameter 16 - CURRENT in Section DESCRIPTION OF PARAMETERS. AUTO/MANUAL MODE The relay energizes when the drive is in the AUTOMATIC mode, and de-energizes in the MANUAL mode. Refer to Section SPEED REFERENCE SELECTION. 18

23 7.0 INSTALLATION DRIVES MUST NOT BE INSTALLED WHERE SUBJECTED TO ADVERSE ENVIRON- MENTAL CONDITIONS! DRIVES MUST NOT BE INSTALLED WHERE SUBJECTED TO: COM- BUSTIBLE, OILY, OR HAZARDOUS VAPORS OR DUST; EXCESSIVE MOISTURE OR DIRT; STRONG VIBRATION; EXCESSIVE AMBIENT TEMPERATURES. CONSULT CUSTOMER SERVICE FOR MORE INFORMATION ON THE SUITABILITY OF A DRIVE TO A PARTICULAR ENVIRONMENT. The drive should be mounted on a smooth vertical surface capable of safely supporting the unit without vibrating. The LCD display has an optimum field of view, this should be considered when determining the mounting position. All drive models MUST be mounted in a vertical position for proper heatsink cooling. Maintain a minimum spacing around the drive of 2 inches for units rated 5 Hp and below, 4 inches for units rated HP, and 6 inches for units rated HP. Fans or blowers should be used to insure proper cooling in tight quarters. Do not mount drives about other drives or heat producing equipment that would impede the cooling of the drive. Note the ambient operating temperature ratings for each drive model. If it is necessary to drill or cut the drive enclosure or panel, extreme care must be taken to avoid damaging drive components or contaminating the drive with metal fragments (which cause shorting of electrical circuits). Cover drive components with a clean cloth to keep out metal chips and other debris. Use a vacuum cleaner to clean drive components after drilling, even if chips do not appear to be present. Do not attempt to use positive air pressure to blow chips out of drive, as this tends to lodge debris under electronic components. Contaminating the drive with metal chips can cause drive failure and will void the warranty. The SpinMaster Micro Series Drives are UL approved for solid state motor overload protection. Therefore, a separate thermal overload relay is not required for single motor applications. In applications where one drive is operating more than one motor, a separate thermal overload relay is required for each motor per NEC. 7.1 INSTALLATION AFTER A LONG PERIOD OF STORAGE Severe damage to the drive can result if it is operated after a long period of storage or inactivity without reforming the DC bus capacitors! If input power has not been applied to the drive for a period of time exceeding three years (due to storage, etc), the electrolytic DP bus capacitors within the drive can change internally, resulting in excessive leakage current. This can result in premature failure of the capacitors if the drive is operated after such a long period of inactivity or storage. In order to reform the capacitors and prepare the drive for operation after a long period of inactivity, apply input power to the drive for 8 hours prior to actually operating the drive/ motor system. 19

24 7.2 EXPLOSION PROOF APPLICATIONS Explosion proof motors that are not rated for inverter use lose their certification when used for variable speed. Due to the many areas of liability that may be encountered when dealing with these applications, the following statement of policy applies: REGAL-BELOIT CORPORATION inverter products are sold with no warranty of fitness for a particular purpose or warranty of suitability for use with explosion proof motors. REGAL-BELOIT CORPORATION accepts no responsibility for any direct, incidental or consequential loss, cost, or damage that may arise through the use of its AC inverter products in these applications. The purchaser expressly agrees to assume all risk of any loss, cost, or damage that may arise from such application. 8.0 INPUT AC REQUIREMENTS Hazard of electrical shock! Disconnect incoming power and wait three minutes before servicing the drive. Capacitors retain charge after power is removed. 8.1 INPUT AC POWER REQUIREMENTS VOLTAGE: The input voltage must match the drive s nameplate voltage rating. Voltage fluctuation must not vary by greater than 10% overvoltage or 15% undervoltage. NOTE: Drives with dual rated input voltage must be programmed for the proper supply voltage. Refer to Parameter 0 - LINE VOLTS in Section DESCRIPTION OF PARAMETERS. The drive is suitable for use on a circuit capable of delivering not more than 200,000 RMS symmetrical amperes, at the drive s rated voltage. Three phase voltage imbalance must be less than 2.0% phase to phase. Excessive phase to phase imbalance can cause severe damage to the drive s power components. Motor voltage should match line voltage in normal applications. The drive s maximum output voltage will equal the input voltage. Use extreme caution when using a motor with a voltage rating which is different from the input line voltage kva RATINGS: If the kva ratings of the AC supply transformer is greater than ten times the input kva rating of the drive, a drive isolation transformer, or a 2-3% input line reactor (also known as a choke) must be added. 20

25 8.2 INPUT FUSING AND DISCONNECT REQUIREMENTS A circuit breaker or a disconnect switch with fuses must be provided in accordance with the National Electric Code (NEC) and all local codes. The SpinMaster Micro drive is capable of withstanding up to 150% current overload for 60 seconds. Select a fuse or magnetic trip circuit breaker rated at 1.5 times the input current rating of the drive (the minimum fuse size should be 10 amps, regardless of input current rating). Refer to section SpinMaster Micro Drive RATINGS. Minimum voltage rating of the protection device should be 250 Vac for 120/240 Vac and 208/240 Vac rated drives, and 600 Vac for 480 Vac and 575 Vac drives. Use Class CC or Class T current limiting fuses with low I 2 T values, rated at 200,000 AIC. Recommended fuses are Bussman type KTK-R, JJN, and JJ s or equivalent. 9.0 VOLTAGE SELECTION 9.1 INPUT VOLTAGE RATINGS SpinMaster Micro Drive catalog numbers T1110-T1115, T400-T405, and T410-T415 are rated for 120/240 Vac (+ 10%, -15%) at 48 to 62 Hz when wired for 120 Vac input, or with input voltage of 240 Vac (+10%, -15%), at 48 to 62 Hz, when wired for 240 Vac input. (Voltage Group A) SpinMaster Micro Drive catalog numbers T1116-T1224, T422-T431, T452-T461, T406, T407, T416, T417, and T532-T534 are rated for 208/240 Vac, Hz input. The drive will function with input voltages of 200 to 240 Vac (+10%, -15%), at 48 to 62 Hz. (Voltage Group B) SpinMaster Micro Drive catalog numbers T1414-T1427, T434-T442, T464-T472, and T532-T534 are rated for 480 Vac, Hz input. The drive will function with input voltages of 400 to 480 Vac (+10%, -15%), at 48 to 62 Hz. (Voltage Group C) SpinMaster Micro Drive catalog numbers T1514-T1527, T444-T453, T474-T482, and T553-T557 are rated for 590/480 Vac, Hz input. The drive will function with input voltages of 480 to 590 Vac (+10%, -15%), at 48 to 62 Hz. (Voltage Group D) 10.0 POWER WIRING Hazard of electrical shock! Disconnect incoming power and wait three minutes before servicing the drive. Capacitors retain charge after power is removed. Note drive input and output current ratings and check applicable electrical codes for required wire type and size, grounding requirements, overcurrent protection, and incoming power disconnect, before wiring the drive. Size conservatively to minimize voltage drop. 21

26 Input fusing and a power disconnect switch or contactor MUST be wired in series with terminals L1, L2, and L3 (L1 and L2 if input is single phase). A disconnect means must be wired during installation. This disconnect must be used to power down the drive when servicing, or when the drive is not to be operated for a long period of time, but should not be used to start and stop the motor. Repetitive cycling of a disconnect or input contactor (more than once every two minutes) may cause damage to the drive WIRING FOR SINGLE PHASE OR THREE PHASE INPUT If the drive is nameplated for 120/240 Vac single phase input, wire the input to terminals L1 and N and jumper terminals L1 to L2 for 120 Vac input voltage, or wire to terminals L1 and L2 (do not wire to N) for 240 Vac input voltage. Refer to Section SpinMaster Micro Drive POWER WIRING DIAGRAM. If the drive is nameplated for three phase input only, wire the input to terminals L1, L2, and L3. All three power output wires, from terminals T1, T2, and T3 to the motor, must be kept tightly bundled and run in a separate conduit away from all other power and control wiring. It is not recommended to install contactors or disconnect switches between the drive and motor. Operating such devices while the drive is running can potentially cause damage to the drive s power components. If such a device is required, it should only be operated when the drive is in a STOP state. If there is potential for the device to be opened while the drive is running, the drive must be programmed for COAST TO STOP (see Parameter 26 - STOP), and an auxiliary contact on the device must be interlocked with the drive s run circuit. This will give the drive a stop command at the same time the device opens, and will not allow the drive to start again until the device is closed. 22

27 11.0 SpinMaster Micro Drive POWER WIRING DIAGRAM L1 L2 N T1 T2 T3 L1 L2 L3 GNDGND 120 Vac SINGLE PHASE INPUT WIRING DIAGRAM L1 L2 N THREE PHASE AC MOTOR GND FUSED INPUT VOLTAGE DISCONNECT MEANS (REQUIRED) 240 Vac SINGLE PHASE INPUT WIRING DIAGRAM Do not connect incoming AC power to output terminals T1, T2, or T3! Severe damage to the drive will result. INSTALL, WIRE, AND GROUND IN ACCORDANCE WITH ALL APPLICABLE CODES. NOTES: 1. Wire the motor for the proper voltage per the output rating of the drive. Motor wires MUST be run in a separate steel conduit away from control wiring and incoming AC power wiring. 2. Do not install contactors between the drive and the motor without consulting REGAL-BELOIT for more information. Failure to do so may result in drive damage. 3. Remove any existing, and do not install, power factor correction capacitors between the drive and the motor. Failure to do so will result in drive damage. 4. Use only UL and CSA listed and approved wire. 5. Minimum wire voltage ratings: 300 V for 120, 200 and 240 Vac systems, and 600 V for 400, 480, and 590 Vac systems. 23

28 6. Wire gauge must be based on a minimum of 150% of the rated output current of the drive, and a minimum 75 C insulation rating. Use copper wire only. 7. Wire and ground in accordance with NEC or CEC, and all applicable local codes INITIAL POWER UP Hazard of electrical shock! Wait three minutes after disconnecting incoming power before servicing drive. Capacitors retain charge after power is removed. Before attempting to operate the drive, motor, and driven equipment be sure all procedures pertaining to installation and wiring have been properly followed. Severe damage to the drive can result if it is operated after a long period of storage or inactivity without reforming DC bus capacitors! If input power has not been applied to the drive for a period of time exceeding three years (due to storage, etc), the electrolytic DC bus capacitors within the drive can change internally, resulting in excessive leakage current. This can result in premature failure of the capacitors if the drive is operated after such a long period of inactivity or storage. In order to reform the capacitors and prepare the drive for operation after a long period of inactivity, apply input power to the drive for 8 hours prior to actually operating the drive/motor system. Disconnect the driven load from the motor. Verify that the drive input terminals (L1, L2, and L3) are wired to the proper input voltage per the nameplate rating of the drive. DO NOT connect incoming AC power to output terminals T1, T2, and T3! Do not cycle input power to the drive more than once every two minutes. Damage to the drive will result. Energize the incoming power line. The LCD display should light and flash TESTING and then show the voltage and horsepower rating of the drive. The display should then show STOP>20.00 HZ which indicates that the drive is in a STOP condition, and the speed setpoint is Hz: 24

29 If the display does not appear, remove the incoming power, wait three minutes for the bus capacitors to discharge, and verify correct installation and wiring. If the wiring is correct, re-apply incoming power and note the display for drive status. If the display still does not appear contact the factory for assistance. NOTE 1: If the drive s display is blank after power up, and it is a model equipped with heatsink fans, check to make sure the fans are operating (they should be spinning anytime power is applied to the drive). If they are not spinning, the drive s display will be blank and the drive cannot be operated. If the fans are clogged or jammed, disconnect power from the drive and remove any obstructions from the fans. Re-apply power to the drive and check the fans. If they are spinning, the drive s display should appear and the drive should operate properly. If there are no obstructions, the fan itself may be defective. Please contact the factory for assistance. If the drive powers up correctly, follow the procedure given below to check the motor rotation: 1. Use the DOWN ARROW key to decrease the speed setpoint to the minimum value allowed (.50 Hz if Parameter 10 - MIN FRQ has not been changed). 2. Press the START key. The drive should indicate RUN, but if the speed setpoint is.50 Hz, the motor may not rotate. Press the UP ARROW key to increase the speed setpoint until the motor starts to rotate. 3. If the motor is rotating in the wrong direction, press the STOP key and remove power from the drive. Wait three minutes for the bus capacitors to discharge, and swap any two of the motor wires connected to T1, T2, and T3. NOTE 2: The drive is phase insensitive with respect to incoming line voltage. Therefore, to change the motor rotation, the phases must be swapped at the drive output terminals or at the motor KEYPAD CONTROL The drive can be operated in a number of different ways: keypad (LOCAL), control devices wired to the terminal strip (REMOTE), serial communications (SERIAL), or a combination of each. The drive should first be operated from the keypad during initial start-up. Refer to Sections CONTROL WIRING, and DESCRIPTION OF PARAMETERS for information on remote operation KEYPAD FUNCTIONS (IN LOCAL MODE) START/STOP To start the drive, press the START key. To stop the drive, press the STOP key. NOTE: The STOP key is active in both LOCAL and REMOTE modes. 25

30 SPEED SETPOINT FORWARD/REVERSE AUTO/MANUAL FAULT RESET To increase speed setpoint, press the key. To decrease the speed setpoint, press the key. NOTE: The and keys will only function if another speed reference source is not selected. To change rotation direction, press the FWD/REV key to select the desired direction, and then press the ENTER key within three seconds to confirm the change. NOTE: Parameter 27 - ROTATION must be set for FWD & REV for this key to be active. To toggle between AUTOMATIC (terminal strip) and MANUAL (keypad) speed control, press the AUTO/MAN key to select the desired mode, and then press the ENTER key within three seconds to confirm the change. NOTE: Parameter 28 - AUTO/MAN must be set to BOTH for this key to be active. See Section CONTROL WIRING for information on automatic speed references. Use the STOP key to reset a fault. If the fault condition has passed, pressing the STOP key will reset the fault and return the drive to a STOP condition. NOTE: If an OUTPUT fault occurs, there will be a 30 second delay before the fault can be cleared using the STOP key SpinMaster Micro Drive DISPLAY The following describes the possible display configurations for the SpinMaster Micro Drive Series SpinMaster Micro Drive DISPLAY IN STOP MODE When the drive is in the STOP mode, there are three possible displays. The first is the SPEED display, which looks like this: NOTE: See Parameter 31 - UNITS for the SPEED UNITS display options. 26

31 Pressing the ENTER key will change the display from the SPEED indication to the % LOAD indication: Pressing the ENTER key again will change the display from the % LOAD indication to the VAC (motor voltage) indication: Pressing ENTER again will change the display back to the SPEED indication. 27

32 The following table shows the possible DRIVE STATUS indications that can appear on the drive display: DRIVE STATUS TABLE DISPLAY DESCRIPTION STOP Drive is in STOP mode - No output to the motor. RUN Drive is in RUN mode and is within ± 3 Hz of the speed setpoint. FAULT Drive has shut down due to a FAULT condition. If the fault condition has passed, pressing the STOP key will clear the fault and return the drive to the STOP mode. LOCK Drive is in FAULT LOCKOUT after five unsuccessful restart attempts. BRAKE DC BRAKE is energized LIMIT Drive is in CURRENT LIMIT due to an overloaded motor, or ACCEL is set too fast. F DEC Drive is in DECEL FREEZE because DECEL rate is too fast. 28